WO2015004752A1

WO2015004752A1 - Production method for molding material, molding die used in said production method, and production method for rotating resin body

Info

Publication number: WO2015004752A1
Application number: PCT/JP2013/068877
Authority: WO
Inventors: 昌也小澤; 匡生杉山; 武司深尾
Original assignee: 新神戸電機株式会社
Priority date: 2013-07-10
Filing date: 2013-07-10
Publication date: 2015-01-15
Also published as: JP5621941B1; US10265886B2; CN105339146B; CN105339146A; US20160200004A1; JPWO2015004752A1

Abstract

Provided is a production method for a molding material that exhibits little variation in the amounts of short fibers and powdered resin in individual products, that does not cause damage to a mold, and that makes continuous production possible. At a loading step, a slurry is supplied toward a slurry dispersion member (7) from above. The slurry dispersion member (7) has a shape in which the area of a cross-section thereof in a direction that extends in the upward direction and that is orthogonal to the upward direction decreases as proximity to the upward direction increases. At a cleaning step, a dispersion medium that is the same as the dispersion medium used in the loading step or water is poured toward the slurry dispersion member (7) from above, thereby causing short fibers and powdered resin that are stuck to the top of the slurry dispersion section (71) of the slurry dispersion member (7) to fall therefrom. The dispersion medium is subsequently discharged from a cylindrical mold (3) and an aggregate (38) of the short fibers and the powdered resin that have accumulated in the cylindrical mold (3) is produced. The aggregate (38) is then compressed.

Description

Manufacturing method of molding material, molding die used in the manufacturing method, and manufacturing method of resin rotating body

The present invention relates to a method for manufacturing a molding material, a method for manufacturing a resin rotating body using the molding material manufactured by the above-described manufacturing method, and a molding die used for the manufacturing method.

In JP 2009-154338 A (Patent Document 1), JP 2009-250364 A (Patent Document 2) and JP 2011-152729 A (Patent Document 3), there are reinforcing fibers made of short fibers, water and A method for manufacturing a resin rotating body is disclosed in which a reinforcing fiber base material (molding material) is formed on the outer peripheral portion of a bush using a slurry in which is mixed. In the methods described in these publications, the slurry is placed in a cylindrical mold containing a metal bush, and the reinforcing fibers are collected around the bush by dehydrating the slurry so that the reinforcing fibers do not leak out. After that, the aggregate is compressed to form a reinforcing fiber substrate (molding material). In particular, in the method described in Japanese Patent Application Laid-Open No. 2011-152729 (Patent Document 3), a slurry diffusing member is disposed in the center of the cylindrical mold. The slurry diffusing member includes a conical slurry diffusing portion at the upper end. Therefore, it can be expected that the slurry can be put into the cylindrical mold without any large variation by throwing the slurry into the molding die from above toward the slurry diffusion portion.

JP 2009-154338 A JP 2009-250364 A JP 2011-152729 A

As in the method described in Patent Document 3, when the viscosity of the slurry is low or the length of the short fiber is short, the slurry diffusing portion is sufficiently effective. However, when the viscosity of the slurry is increased or the length of the short fiber is increased, there is a high possibility that the slurry containing the short fiber remains on the slurry diffusion portion. When short fibers remain on the slurry diffusion portion, there is a problem that the amount of short fibers per product varies. Furthermore, when the fiber assembly is compressed, there is a problem that the material is caught by the short fiber in the gap between the mold members, the mold is damaged, and continuous production cannot be performed.

An object of the present invention is to provide a method for producing a molding material that can be continuously produced without damage to the mold.

Another object of the present invention is a method for producing a molding material capable of performing continuous production with little variation in the amount of individual short fibers and powdered resin, no damage to the mold, and molding used in the production method. The purpose is to provide molds.

Moreover, it aims at providing the manufacturing method of the resin-made rotary body and the resin-made rotary body manufactured by this manufacturing method which pressed and heated the molding raw material, and melted and hardened the powdery resin. .

The manufacturing method of the molding material of the present invention performs the following adjustment process, charging process, cleaning process, discharging process and compression process. In the adjustment step, a slurry is prepared in which short fibers and powdered resin are dispersed in a dispersion medium. In the charging step, the cylindrical mold having an opening that opens upward, and the area of the cross section that is arranged in the center of the cylindrical mold and extends upward and is orthogonal to the upward direction is upward. Into a molding die including a slurry diffusing member having a slurry diffusing portion having a shape that becomes smaller as it goes toward, the slurry is thrown from above toward the slurry diffusing portion.

In the washing process, after the charging process, the same dispersion medium or water as the dispersion medium is poured from above toward the slurry diffusion part to drop the short fibers and the powdered resin adhering to the slurry diffusion part. When such a cleaning process is performed, the slurry or short fibers remaining on the slurry diffusion portion can be surely dropped from the slurry diffusion portion, so that the occurrence of so-called material biting can be prevented. Therefore, it is possible to provide a manufacturing method of a molding material that can be continuously produced without damage to the mold. The amount of the dispersion medium or water to wash away the short fibers and the powdered resin is added at a predetermined time interval so that the dispersion medium or water does not overflow from the mold, and the number of injections of the dispersion medium or water is 2 By setting the number of times or more (multiple times), the short fibers and the powdered resin remaining on the upper portion of the slurry diffusing member 7 can be surely washed away. And the predetermined time interval when injecting the dispersion medium or water twice or more is more than the upper surface of the aggregate of the short fibers and the powdered resin in which the liquid surface of the dispersion medium or water previously injected is accumulated in the mold. Determined as the time interval required to go down.

In the discharging step, the dispersion medium or the dispersion medium and water are discharged from the molding die to form an aggregate in which short fibers and powdered resin are aggregated in the molding die. The discharging step is preferably performed under a reduced pressure atmosphere. A method of putting slurry into such a mold and draining the mold is called a filtration dehydration method. The filtration dehydration method is a method in which a slurry containing short fibers is placed in a predetermined container and the slurry in the container is dehydrated while being filtered to form an aggregate of short fibers and a powdered resin. is there. When an aggregate of short fibers and powdered resin is produced by such a method, a boundary portion that causes peeling is not formed in the central portion of the molding material. In the compression process, the aggregate is compressed to form a molding material during the discharge process or after the discharge process. The compression step is preferably performed at a pressure of 5 to 25 MPa. The compression process is preferably performed while applying heat at a temperature lower than the melting temperature of the powdered resin. When an assembly of short fibers and a powdered resin is continuously compressed using the same apparatus, it is not necessary to handle an assembly that is bulky and weak (easy to lose shape). Less is enough.

In addition, various materials and types can be used as the short fibers. In the claims of the present application, the term “short fiber” includes not only a fiber having a literally short length but also a case of containing fine fibers and / or pulp-like fibers obtained by fibrillating the fibers.

As the powdered resin, various materials such as a thermosetting resin and a thermoplastic resin can be used. The particle shape of the powdery resin is arbitrary, but a granular resin is preferably used. The particle diameter varies depending on the fiber diameter of the short fibers, but a particle diameter that can be uniformly distributed in the gaps of the short fiber aggregates is preferable. When the particle diameter is large, the fiber orientation of the aggregate of short fibers is disturbed, or when forming a resin molded body by heat and pressure molding, the short fibers and the resin inside the molded body may not be uniformly distributed. It is.

Also, the slurry may be adjusted by adding one or more types of electrostatic attraction aggregation type polymer flocculant (polymer-flocculating agent) to a mixture of short fibers, powdered resin, and water. In this case, as the slurry diffusing member, it is preferable to use a member having a curved surface that protrudes upward at the tip of the slurry diffusing portion. When an electrostatic attractive aggregation type polymer flocculant is added, the polymer flocculant functions not only as an aggregating function but also as a fixing agent (fixing agent). The resin is fixed. As a result, the amount of short fibers and powdered resin remaining in the aggregate can be increased. That is, the fixing ratio between the short fibers and the powdered resin can be increased. In addition, according to the present invention, the slurry diffusing member provided with the slurry diffusing portion having the curved surface at the tip portion is used, and the slurry is adjusted by adding a polymer flocculant to perform the cleaning step. Even if the viscosity of the slurry increases, short fibers and powdered resin do not remain on the slurry diffusion portion.

In addition, it is preferable that the curvature radius of the curved surface provided in the front-end | tip of the slurry diffusion part of the slurry diffusion member in a shaping | molding die is 10 mm or more and 20 mm or less. If the radius of curvature is smaller than this range, there is a possibility that a large number of flocs formed by gathering some short fibers and some powdered resin are stuck in the tip of the slurry diffusion part. high. When the radius of curvature is larger than this range, flocs are likely to be deposited on the slurry nucleic acid part.

As one or more types of electrostatic attraction aggregation type polymer flocculant, after adding cationic polymer flocculent agent to the mixture, anionic polymer flocculant agent (anionic polymer floculating agent) Is preferably added. When a cationic polymer flocculant is added to the mixed solution, a large number of aggregates called flocs are formed which are formed by collecting some short fibers and some powdered resin. Thereafter, when an anionic polymer flocculant is added, flocs gather to form a larger floc, and a large number of flocs having larger dimensions are formed. When such a floc is formed, the dewaterability is improved. As a result, dehydration can be performed in a short time, and the fixing rate between the short fibers and the powdered resin is improved. In particular, when a cationic styrene polymer aqueous solution is used as the cationic polymer flocculant and an anionic acrylic polymer aqueous solution is used as the anionic polymer flocculant, high dehydrating properties can be obtained.

It should be noted that an amphoteric polymer flocculating agent may be used as the one or more types of electrostatic attraction aggregation type polymer flocculants. Amphoteric polymer flocculants are the neutralization effect (cations) of short fibers and powdered particles in the mixture, the formation of entanglement (high molecular weight) by polymer chains, and the entanglement (high molecular weight). It exerts an effect of reinforcing by electrostatic attraction due to charges of anions and cations.

The opening of the cylindrical mold may be closed by a lid member having a nozzle extending downward in the center. In this case, the length and the tip shape of the nozzle are determined so that the dispersion medium or water is concentrated on the slurry diffusion portion in the cleaning process. If it does in this way, a dispersion medium or water can be effectively applied on a slurry diffusion part from a nozzle, and a short fiber and powdery resin can be dropped below on a slurry diffusion part more reliably.

The molding material produced by the production method of the present invention is heated and pressurized to melt the powdered resin, impregnated with a molten resin layer made of short fibers, and then the molten resin is cured. A resin-made rotating body can be manufactured by further performing a molding step for forming the resin-molded body. And a resin-made gear can be manufactured by performing a gear cutting process process to the outer peripheral part of a resin molding after a shaping | molding process.

(A) thru | or (D) is a schematic process drawing which shows operation | movement of the filtration dehydration compression apparatus used by embodiment of this invention. (A) And (B) is a figure which shows the modification of a slurry spreading | diffusion part. It is a longitudinal cross-sectional view of the resin-made gear manufactured by embodiment of this invention. FIG. 4 shows a metal bush of the resin gear shown in FIG. 3, (A) shows a plan view, and (B) shows a longitudinal sectional view. (A) shows the longitudinal cross-sectional view of the shaping | molding raw material integrated with the bush, (B) shows the longitudinal cross-sectional view of a filtration dehydration compression apparatus. It is a general | schematic process figure which shows the preparation process of the resin gears which are one Example of this invention.

Hereinafter, an example of the filtration dehydration compression apparatus used in this manufacturing method will be described before the method for manufacturing the molding material of the present invention is described.

<Filtering dehydration compression device>
The filtration dehydration compression apparatus 13 used in the method for producing a molding material according to the present invention includes, as shown in FIG. 1, for example, a molding die including a pedestal 1, a hollow lower compression mold 2, a cylindrical mold 3, and a hollow upper compression mold 4. Is used. The hollow lower compression mold 2 includes a bush support 5 and a lower elastic body 6 therein. The cylindrical mold 3 is provided with a slurry diffusion member 7 therein. Further, the hollow upper compression mold 4 includes a pressing member 8 and an upper elastic body 9.

Hereinafter, each member will be described in detail.

(pedestal)
The pedestal 1 supports the entire filtration dehydration compression apparatus, and the hollow lower compression mold 2 is directly placed on the upper surface of the pedestal 1 as long as it can be placed horizontally with little distortion due to load. There is no particular limitation.

The material of the pedestal 1 is not particularly limited, but stainless steel, carbon steel, aluminum, aluminum alloy, magnesium alloy and the like can be used, and stainless steel is preferably used from the viewpoint of corrosion resistance.

The size of the pedestal 1 is not particularly limited.

(Hollow compression type)
The hollow lower compression mold 2 is installed on the upper surface of the base 1 described above, and various methods such as bolt fixing, groove fixing, fitting fixing, and welding can be used as the installation method. From the viewpoint of ease of disassembly, it is preferable to fix the hollow lower compression mold 2 to the base 1 with a plurality of bolts.

The hollow lower compression mold 2 has a hollow part opened in the vertical direction inside. In this hollow portion, a bush support 5 on which the bush 31 is placed is arranged.

The lower surface of the bush support base 5 is supported by a lower elastic body 6 erected on the base 1, and the height from the base 1 can be changed by the expansion and contraction of the lower elastic body 6. The lower elastic body 6 may be erected not only directly on the pedestal 1 but also indirectly on the pedestal 1. Further, a plurality of lower elastic bodies 6 may be installed.

As described above, the lower elastic body 6 only needs to change the height of the bush support 5 by expansion and contraction, and a coil spring, a disc spring, a leaf spring, a molded body of natural / synthetic rubber, or the like is used. Can do. In use conditions in which a high compressive force is applied to the lower elastic body 6, a spring is preferable in terms of durability. The material of the spring is not particularly limited, but stainless steel excellent in corrosion resistance and a spring subjected to rust prevention treatment are preferable. A rubber spring or the like can also be used.

The bush support 5 is for mounting the bush 31 on the upper surface thereof, and one having a groove for preventing the displacement of the bush 31 can be preferably used. If the bush 31 is a magnetic body, a magnet can be used instead of the groove.

Further, the connection between the bush support 5 and the lower elastic body 6 may be performed by adhesion or fixation. It is preferable that the bush support 5 and the lower elastic body 6 are detachably connected so that the bush support can be exchanged according to the type of the bush 31.

The relationship between the hollow lower compression mold 2 and the bush support base 5 is that at least a part of the bush support base 5 enters the hollow portion of the hollow lower compression mold 2 when viewed from the horizontal direction. The amount of insertion of the bush support 5 into the hollow portion changes due to expansion and contraction. During normal operation, when the bush support 5 is separated from the hollow portion of the hollow lower compression mold 2 when viewed from the horizontal direction due to the extension of the lower elastic body 6, the bush support is supported by the contraction of the lower elastic body 6. When the table 5 returns to the hollow lower compression mold 2, there is a possibility that a position shift occurs, which is not practical.

A step 10 is provided on the inner wall of the hollow lower compression mold 2 in which the hollow portion is formed. The step portion 10 is in contact with the lower portion of the bush support base 5 to prevent the bush support base 5 from being lowered due to expansion and contraction of the lower elastic body 6. The step portion 10 is preferably formed by changing the inner diameter of the hollow portion or by providing a protrusion on the inner wall.

In addition, the step part 10 does not necessarily need to be provided over the entire circumference of the inner wall of the hollow lower compression mold 2, and may be provided on a part of the inner wall. When providing the step part 10 in a part of inner wall, in order to maintain the level of the bush support stand 5, it is preferable to provide in three or more places at equal angular intervals.

The position of the stepped portion 10 can be changed depending on the final thickness of the aggregate of short fibers and powdered resin. The step portion 10 is preferably provided at a position where a molding material layer having a thickness equal to the vertical direction can be formed from the center in the thickness direction of the bush 31. Specifically, the position of the step portion 10 of the hollow lower compression mold 2 and the step portion 11 of the hollow upper compression mold 4 described later are in contact with the step portion 10 of the hollow lower compression mold 2 and the bush support 5. The distance from the upper end of the hollow lower compression mold 2 to the center of the bush thickness direction, and the lower end of the hollow upper compression mold 4 when the stepped portion 11 of the hollow upper compression mold 4 and the pressing member 8 are in contact with each other. It is preferable to make the distance to the center in the thickness direction equal.

The upper surface of the hollow lower compression mold 2 is a bottom portion into which a slurry to be described later is introduced, except for the upper open portion of the hollow portion. Therefore, it is preferable to provide a discharge port 12 for discharging the liquid component in the slurry on the upper surface of the hollow lower compression mold 2. It is more preferable to connect a vacuum suction pump to the discharge port 12. When such a hollow lower compression mold 2 is used, the filtration dehydration time can be further shortened.

(Cylindrical mold)
The cylindrical mold 3 has an opening opened up and down, and the hollow lower compression mold 2 is inserted into the lower opening so as to be in close contact with the outer periphery, and the slurry is outside the mold. To prevent leakage. In addition, the hollow upper compression type | mold 4 mentioned later is inserted in an upper opening part.

The cylindrical mold 3 is made of the same material as that of the hollow lower compression mold 2 because it is necessary to consider the coefficient of thermal expansion and the like and further to make the compression strain ratio the same as that of the hollow lower compression mold 2. Is preferably used.

The vertical length of the cylindrical mold 3 is not particularly limited, but it should be high enough not to leak at least when a predetermined amount of slurry is inserted when the slurry is charged.

A slurry diffusing member 7 is disposed at the center inside the cylindrical mold 3. The slurry diffusing member 7 is located on the upper surface of the bush 31 placed on the bush support 5, and the lower surface thereof has a groove for preventing the displacement of the bush as described in the upper surface of the bush support 5. What has been dug can be preferably used. If the bush 31 is a magnetic body, a magnet can be used instead of the groove.

The slurry diffusing member 7 includes a slurry diffusing portion 71 at its upper end. The slurry diffusion portion 71 has a shape that extends in the upward direction and becomes smaller as the cross-sectional area in the direction orthogonal to the upward direction becomes upward. In the example of FIG. 1 (B), the slurry diffusion portion 71 has a conical shape with the top portion located above. The cone-shaped top portion has a curved surface with a radius of curvature of 10 mm or more and 20 mm or less. When the slurry is introduced into the cylindrical mold 3 from above toward the slurry diffusion portion 71, the aggregated short fibers and the powdered resin are not even caught by the upper end of the slurry diffusion member, and the slurry is evenly distributed around the bush. The short fibers and the powdered resin can be dispersed. Further, the surface shape of the slurry diffusion portion 71 ′ may be a hemispherical shape as shown in FIG. Further, as shown in FIG. 2B, the tip portion may be a convex curved surface, and the base portion may be a curved surface 71 ″ that becomes concave toward the outside.

The slurry diffusing member 7 does not need to be fixed to the upper surface of the bush 31 as long as it does not shift in position, and may simply be placed.

(Hollow top compression type)
The hollow upper compression mold 4 is disposed opposite to the hollow lower compression mold 2 and is inserted into the upper opening of the cylindrical mold 3. The outer periphery of the hollow upper compression mold 4 and the inner wall of the cylindrical mold 3 are in close contact with each other when the hollow upper compression mold 4 is inserted, and prevent leakage of slurry.

In addition, the material of the hollow upper compression mold 4 needs to have the same compressive strain rate as that of the hollow lower compression mold 2 and the cylindrical mold 3 in consideration of the thermal expansion coefficient and the like. It is preferable to use the same material as that of the compression mold 2 and the cylindrical mold 3.

The hollow upper compression mold 4 has a pressing member 8 in its hollow portion, and this pressing member 8 comes into contact with the slurry diffusion portion 71 of the slurry diffusion member 7. The upper surface of the pressing member 8 is supported by the upper elastic body 9, and the position of the pressing member 8 changes as the upper elastic body 9 expands and contracts.

The upper elastic body 9 may be the same as or different from the lower elastic body 6 described above. Note that the upper elastic body 9 is preferably a spring in terms of durability under the use conditions in which the hollow lower compression mold 2 is heated or a high compressive force is applied to the elastic body. Further, it is preferable that the upper elastic body 9 and the lower elastic body 6 are springs having the same spring constant. By doing so, compression from above and compression from below are performed at the same speed, and variations in the density of the short fibers and the powdered resin in the vertical direction can be reduced.

Further, the pressing member 8 and the upper elastic body 9 may be connected by adhesion or fixation. It is preferable that the pressing member 8 and the upper elastic body 9 are detachably connected so that the pressing member 8 can be exchanged according to the type of the bush 31.

The relationship between the hollow upper compression mold 4 and the pressing member 8 is that at least a part of the pressing member 8 enters the hollow portion of the hollow upper compression mold 4 when viewed from the horizontal direction, and the upper elastic body 9 expands and contracts. The insertion amount of the pressing member 8 into the hollow portion changes. During normal operation, when the pressing member 8 moves away from the hollow portion of the hollow upper compression mold 4 as viewed from the horizontal direction due to the extension of the upper elastic body 9, the pressing member 8 is contracted due to the upper elastic body 9 being contracted. Is likely to cause a position shift when returning into the hollow upper compression mold 4 and is not practical.

A step portion 11 is provided on the inner wall of the hollow upper compression mold 4 in which the hollow portion is formed. The step portion 11 is in contact with the upper portion of the pressing member 8 to prevent the pressing member 8 from rising due to the expansion and contraction of the upper elastic body 9. The step portion 11 is preferably formed by changing the inner diameter of the hollow portion of the hollow upper compression mold 4 or by providing a protrusion on the inner wall.

In addition, the step part 11 does not necessarily need to be provided over the perimeter of the inner wall of the hollow upper compression mold | type 4, and can also be provided in a part of inner wall. When providing the step part 11 in a part of inner wall, in order to maintain the horizontal of the pressing member 8, it is preferable to provide in three or more places at equal angular intervals.

As described in the step 10 of the hollow lower compression mold 2, the position of the step 11 is the position of the step 10 of the hollow lower compression mold 2 and the step 11 of the hollow upper compression mold 4. The distance from the upper end of the hollow lower compression mold 2 to the center of the bush thickness direction when the step 10 of the hollow lower compression mold 2 and the bush support 5 are in contact with each other, and the step 11 of the hollow upper compression mold 4 The distance from the lower end of the hollow upper compression mold 4 to the center of the bush thickness direction when the member 8 is in contact is preferably set to be equal.

The temperature of the lower surface of the hollow upper compression mold 4 can be adjusted. By heating at the time of pressure compression, the liquid component adhering to the short fiber and the powdered resin can be quickly dried. At this time, heating temperature shall be below the melting temperature of the powdery resin to be used. This is because if the resin is heated at a temperature exceeding the melting temperature of the powdery resin, the resin adheres to the lower surface of the hollow upper compression mold 4 and the inner peripheral surface of the cylindrical mold 3, making continuous production difficult.

The temperature adjustment may be performed by changing the resistance value of the heater using a variable resistor, or simply by controlling the heater on and off.

(Slurry injection upper mold)
The filtration dehydration compression apparatus can include a slurry injection upper mold 20 that constitutes a lid member for injecting slurry as required (see FIG. 1B). The slurry injection hole 21 of the slurry injection upper mold 20 is located above the slurry diffusion member 7 in order to produce a molding material in which the basis weight of the short fibers and the powdery resin accumulated around the bush 31 is uniform. As in the present embodiment, it is preferable to dispose the slurry injection hole 21 immediately above the slurry diffusion member 7.

In the present embodiment, a nozzle 22 having a through hole 23 communicating with the slurry injection hole 21 is fixed to the back surface of the slurry injection upper mold 20. The tip of the nozzle 22 extends toward the slurry diffusing member 7, and the length and the tip shape are determined so that a dispersion medium or water is intensively introduced onto the slurry diffusing portion 71 in a cleaning process described later. Yes. Specifically, the end surface of the tip portion of the nozzle 22 has a shape that widens as it approaches the slurry diffusion portion 71 (the cross-sectional area in the direction perpendicular to the vertical direction increases as it approaches the slurry diffusion portion 71). The distance between the end face of the tip of the nozzle 22 and the surface of the slurry diffusion part 71 is arbitrarily determined according to the viscosity of the slurry, the length of the short fibers, and the like.

The nozzle 22 is provided when the short fibers and the powdery resin remain attached to the slurry diffusion portion 71 of the slurry diffusion member 7 after the slurry is charged. In order to prevent the short fibers and the powdered resin from being caught between the molds and damaging the molds during the compression step), the dispersion medium or water is concentrated and efficiently in the slurry diffusion part 71. This is to realize that it is put into the system. That is, when the nozzle 22 is provided, the short fibers and the powdered resin attached to the slurry diffusion member 7 can be efficiently dropped in a small amount when the dispersion medium or water is injected from the nozzle 22 after the slurry is charged.

Further, it is preferable that the slurry injection upper mold 20 has a structure in which the slurry injection upper mold 20 is in close contact with the peripheral edge of the opening of the cylindrical mold 3 when the slurry is charged. This prevents slurry from overflowing from the cylindrical mold 3.

<Bush>
The bush 31 is sandwiched between the bush support 5 and the slurry diffusion member 7. Hereinafter, the bush 31 will be described in detail.

The bush is positioned at the center in the radial direction of the molding material. If the final desired one is a resin gear, it is fixed to the rotating shaft and used. The material of the bush is not particularly limited, but a metal is preferable in view of strength.

FIG. 3 is a longitudinal sectional view of the resin gear 30 schematically shown. The resin gear 30 includes a metal bush 31 that is fixed to a rotating shaft (not shown) and rotates. A through hole 32 into which a rotating shaft (not shown) is fitted is formed at the center of the metal bush 31.

Further, on the outer peripheral portion of the metal bush 31, protrusions 33 constituting a plurality of detent portions are integrally formed with a predetermined interval in the circumferential direction.

The metal bush 31 will be described with a specific example. The thickness dimension L2 measured in the axial direction of the plurality of protrusions 33 is smaller than the thickness dimension L1 measured in the axial direction of the metal bush 31. . And the protrusion part 33 which comprises a rotation prevention part is an undercut shape with a thick top part and a thin base part. This undercut prevents interface breakage from occurring at the interface with the surrounding resin molding part and prevents only the metal bush 31 from spinning around. The angle θ of the metal bush 31 in the cross section in the rotation axis direction is The one of 5 to 40 ° is used.

In order to enhance the action of the anti-rotation portion that can withstand the load in the rotation direction, as shown in FIG. 4, the protrusion 33 serving as the anti-rotation portion includes at least a protrusion 33 having a height h 1 and two protrusions 33. It is preferable that the recesses 34 formed between them and having a bottom portion having a height h2 are alternately arranged. When the projecting portion 33 having such an undercut shape and an angle θ of 5 to 40 °, preferably 10 to 35 ° is used, a plurality of projecting portions 33 as rotation preventing portions are formed in the molding material. It becomes a completely filled state, and the strength of the mechanical bond between them can be made sufficient.

<Slurry>
Next, the slurry used in this embodiment will be described. Note that the present invention is not limited to using the slurry used in the present embodiment.

(Slurry dispersion)
The dispersion medium used for the slurry is not particularly limited as long as it can disperse the short fibers and the powdered resin and does not deteriorate the properties of the short fibers and the powdered resin used. For example, as the dispersion medium, an organic solvent, a mixture of an organic solvent and water, water, or the like can be used. It is particularly preferable to use water that is economical and has a low environmental impact.

When using an organic solvent, it is possible to use an organic solvent such as methanol, ethanol, acetone, toluene, diethyl ether, etc. with careful attention to safety.

The slurry may be adjusted by adding one or more types of electrostatic attraction aggregation type polymer flocculants to a mixed liquid obtained by mixing short fibers, powdered resin, and a dispersion medium.

(Short fiber)
The short fibers dispersed in the dispersion medium are preferably made of short fibers having a melting point or decomposition temperature of 250 ° C. or higher. By using such short fibers, a molding material or resin gear having excellent heat resistance can be obtained without causing thermal deterioration of the short fibers at the molding temperature and processing temperature during molding and the ambient temperature during actual use. be able to.

Such short fibers include para-aramid fibers, meta-aramid fibers, carbon fibers, glass fibers, boron fibers, ceramic fibers, ultra-high strength polyethylene fibers, polyketone fibers, polyparaphenylene benzobisoxazole fibers, wholly aromatic. It is preferable to use at least one kind of short fiber selected from polyester fiber, polyimide fiber, and polyvinyl alcohol fiber, especially when a mixed fiber of para aramid fiber and meta aramid fiber is used. Has an excellent balance of heat resistance, strength, and workability after resin molding.

The short fiber preferably contains at least 20% by volume or more of high-strength and high-modulus fiber having a tensile strength of 15 cN / dtex or more and a tensile modulus of 350 cN / dtex or more.

The single fiber fineness (thickness) of the short fiber is preferably in the range of 0.1 to 5.5 dtex, more preferably in the range of 0.3 to 2.5 dtex.

The length of the short fiber is not particularly limited, but is preferably 1 to 12 mm, and more preferably 2 to 6 mm. When the fiber length is less than 1 mm, the mechanical properties of the fiber reinforced resin molded product are gradually lowered. When the fiber length exceeds 12 mm, the short fibers are too entangled, making it difficult to form a uniform formation, and also piping for transferring the short fibers dispersed in the dispersion to the filtration dehydration compression device Of these, clogging due to short fibers tends to occur gradually, which is not preferable.

The ratio of the short fibers contained in the resin molding is preferably selected so that the short fibers are strong, the short fibers are surely filled, and the impregnation of the resin is not inhibited, and 35 to 45% by volume is particularly preferable.

In order to give strength to maintain the shape when moving or transporting the molding material 35 integrally formed with the metal bush 31 to the next process using the filtration dehydration compression apparatus shown in FIG. In addition, the short fibers include fine fibers obtained by fibrillating aramid fibers, the fineness of the fine fibers is 100 to 400 ml, and the fine fiber content is 30% by mass or less in the short fibers. Is desirable.

(Powder resin)
As the powdered resin, various materials such as a thermosetting resin and a thermoplastic resin can be used. For example, epoxy resin, polyaminoamide resin, phenol resin, unsaturated polyester resin, polyimide resin, polyethersulfone resin, polyetheretherketone resin, polyamideimide resin, polyamide resin, polyester resin, polyphenylene sulfide resin, polyethylene resin, polypropylene A combination of one or more resins selected from resins can be used. Among these, a phenol resin is preferable from the viewpoints of the strength and heat resistance of the cured resin.

The particle shape of the powdered resin is arbitrary, but it is preferable to use a granular one. Moreover, although a particle diameter changes with fiber diameters of a short fiber, 50 micrometers or less are preferable. The particle diameter was measured by a metal mesh sieving method defined in JIS-Z8801-1. Thereby, powdery resin can be uniformly distributed in the gaps between the aggregates of short fibers.

(Dispersion concentration of short fiber and powdered resin)
The dispersion concentration of the short fibers and the powdered resin in the dispersion medium is preferably 0.3 g / liter or more and 20 g / liter or less.

<Resin rotating body>
Hereinafter, a resin gear that is suitably manufactured using the molding material manufactured in the present embodiment will be described.

The resin rotating body is a resin molded body obtained by impregnating a reinforcing fiber layer made of short fibers with a molten resin produced by pressurizing a molding material while heating to melt a powdered resin, and then curing the molten resin. Is formed. Further, a gear cutting process can be performed on the outer peripheral portion of the resin molded body to form a gear shape. More specifically, one having a metal bush 31 fitted to a rotating shaft for rotating a gear and a tooth portion arranged around the metal bush can be preferably used.

The tooth portion is arranged on the outer periphery of the metal bush described above. More specifically, with reference to FIG. 3 described above, one molding material 35 is arranged at a position outside the outer peripheral portion 36 of the metal bush 31 in a state of being fitted to the outer peripheral portion 36. . The molding material 35 becomes a resin molding 37 formed by being impregnated with resin and cured. The tooth portion is formed on the outer periphery of the resin molded body 37.

<Drive of filtration dehydration compression device>
The filtration dehydration compression apparatus 13 has a drive device that can change the separation distance between the hollow lower compression mold 2 and the hollow upper compression mold 4 described above. The drive source is not particularly limited, and an electric press machine capable of controlling the moving speed and the applied pressure can be used as the drive source.

Further, although the hollow lower compression mold 2 and the hollow upper compression mold 4 may be driven, it is preferable to drive the hollow upper compression mold 4 up and down because it is easy to disassemble and clean.

<Method for Producing Molding Material of First Embodiment>
Hereinafter, a first embodiment of a method for producing a molding material according to the present invention will be described.

As schematically shown in FIG. 1 and FIG. 3, the molding material 35 uses a filtration dehydration compression device 13 to place a collection 38 of short fibers and powdered resin on the outer position of the outer peripheral portion 36 of the metal bush 31. It is formed by compressing the aggregate 38 of the short fibers and the powdered resin in the axial direction of a rotating shaft (not shown) for rotating the metal bush 31.

First, a charging process in which short fibers and powdered resin are accumulated around the outer periphery of the metal bush 31 by a filtration dehydration method will be described.

<Input process>
In the charging step, the slurry is charged from above into the cylindrical mold 3 toward the slurry diffusing member 7. This slurry is temporarily stored in the cylindrical mold, or the dispersion medium is discharged out of the cylindrical mold in parallel with the addition.

As shown in FIG. 1B, the hollow lower compression mold 2 has a discharge port for discharging the dispersion medium in order to impart the liquid permeability of the dispersion medium contained in the aggregate 38 of short fibers and powdered resin. 12. A vacuum suction pump (not shown) is attached to the discharge port 12, and the discharge of the dispersion medium can be completed in a short time. In this example, a bottom member 39 is disposed on the upper surface of the hollow lower compression mold 2 in order to prevent short fibers from flowing out when the dispersion medium is discharged from the discharge port 12.

A metal mesh can be used for the bottom member 39. The mesh size of the wire mesh is preferably 10 mesh or more and 100 mesh or less. In addition, the mesh size used in the present specification conforms to that defined in JIS G 3555.

The bush support 5 and the slurry diffusing member 7 have a portion located inside the outer peripheral portion 36 of the metal bush 31 so that the short fibers and the powdered resin do not enter inside the outer peripheral portion of the metal bush 31. The cylindrical mold 3 is supported by being sandwiched from both sides in the direction in which the center line extends.

When the metal bush 31 is sandwiched between the bush support 5 and the slurry diffusion member 7, as shown in FIG. 1B, the slurry diffusion member 7 is placed on the bush, and the weight of the slurry diffusion member 7 is set. The metal bush 31 is sandwiched.

As shown in FIG. 1B, the slurry formed by dispersing the short fibers and the powdered resin in the dispersion medium is brought into close contact with the peripheral edge of the opening of the cylindrical mold 3, and the slurry injection upper mold 20 is brought into close contact with the slurry. It is supplied from the injection hole 21.

The slurry is supplied toward the slurry diffusing member 7 from above, whereby the short fibers and the powdered resin are diffused by the slurry diffusing portion 71 and spread evenly distributed around the slurry diffusing member 7.

<Washing process>
In the cleaning step, the same dispersion medium or water as the dispersion medium used in the charging step is poured toward the slurry diffusion member 7 from above, and the short fibers and powder adhering to the slurry diffusion portion 71 of the slurry diffusion member 7 are poured. Drop the resin.

After the slurry is charged in the charging process, the short fibers and the powdered resin remain attached to the upper portion of the slurry diffusion portion 71 of the slurry diffusion member 7. When the short fibers and the powdery resin remain in the slurry diffusion member 7, the hollow upper compression mold 4 and the pressing member 8 are compressed in the compression step of compressing the aggregate of the short fibers and the powdery resin during or after the dispersion medium is discharged in the discharge step. In short, the short fiber and the powdered resin are caught between the slurry diffusion member 7 and the slurry diffusion member 7. When such biting occurs, the mold is damaged and continuous production cannot be performed. Therefore, after the slurry is introduced, the same dispersion medium or water as the slurry dispersion medium is injected from the slurry injection hole 21 through the nozzle 22, and the short fibers and powdered resin remaining on the upper surface of the slurry diffusion portion 71 of the slurry diffusion member 7 are injected. Wash away.

The injection timing of the dispersion medium or water to wash away the short fibers and the powdered resin is input at the timing when the liquid level of the slurry in the mold reaches the upper surface of the aggregate of the short fibers and the powdered resin accumulated in the mold. It is preferable to do this.

The amount of the dispersion medium or water to wash away the short fibers and the powdered resin is introduced in a small amount so that the dispersion medium or water does not overflow from the mold, and the number of injections of the dispersion medium or water is at least twice (multiple times). Thus, the short fibers and the powdered resin remaining on the upper portion of the slurry diffusing member 7 can be surely washed away.

In the case where the dispersion medium or water is injected more than once, the interval between the dispersion medium or water injected before the dispersion medium or water is lowered to the upper surface of the aggregate of short fibers and powdered resin accumulated in the mold. preferable.

<Discharge process and compression process>
In the discharging step, the dispersion medium is discharged from the cylindrical mold 3 to form an aggregate 38 of short fibers and powdered resin in which short fibers and powdered resin are accumulated in the cylindrical mold 3.

In the compression step, a step of compressing the aggregate 38 of short fibers and powdered resin is performed.

More specifically, as shown in FIG. 1 (B), the inside of the cylindrical mold 3 is vacuum-sucked and the liquid component is discharged from a plurality of discharge ports 12 provided in the hollow lower compression mold 2. Thus, an aggregate 38 of short fibers and powdered resin surrounding the periphery of the outer periphery of the metal bush 31 is produced.

If the bush support 5 and the slurry diffusion member 7 are used in this way, the metal bush 31 can be positioned and supported easily.

Further, the shape of the outer peripheral surface of the aggregate 38 of short fibers and powdered resin is determined by the shape of the inner peripheral surface of the cylindrical mold 3.

After the liquid is discharged from the plurality of discharge ports 12 provided in the hollow lower compression mold 2, the bush support 5, the slurry diffusion member 7, and the hollow lower compression mold 2 are moved upward as shown in FIG. Moving. Then, first, the slurry diffusing member 7 and the pressing member 8 come into contact with each other, and the metal bush 31 is fixed by the force of the upper elastic body 9 and the lower elastic body 6. In FIG. 1, springs having the same spring constant are used as the upper elastic body 9 and the lower elastic body 6.

Further, the bush support 5, the slurry diffusing member 7, and the hollow lower compression mold 2 are raised, and the step 10 provided on the bush support 5 and the hollow lower compression mold 2, the pressing member 8, and the hollow upper compression mold 4 are provided. The step portion 11 is brought into contact with the hollow upper compression mold 2 and the hollow upper compression mold 4 so that the distance is not reduced (see FIG. 1D).

Here, the thickness of the molding material will be described in detail with reference to FIG.

As shown in FIG. 5 (A), the relationship between the thickness T1 of the metal bush 31 and the thickness (thickness during compression) T2 of the molding material 35 determined by the stepped portions 10 and 11 (see FIG. 1) is: It is possible to arbitrarily select from three patterns (A) T1 = T2, (B) T1> T2, and (C) T1 <T2.

Further, the relationship between the distance T3 from the lower surface of the metal bush 31 to the lower surface of the molding material 35 during compression and the distance T4 from the upper surface of the metal bush 31 to the upper surface of the molding material 35 during compression is (D) T3 = T4, (E) T3> T4, and (F) T3 <T4 can be arbitrarily selected from the three patterns, and the heights L3 and L4 of the stepped portions 10 and 11 (see FIG. 5B). It becomes possible by changing.

Furthermore, it is also possible to make a specification combining (A) to (C) and (D) to (F) described above.

The time and temperature at which compression is performed can be arbitrarily changed depending on the type of short fiber and powdered resin to be used. At the time of compression, filtration is performed by attaching a heater to the hollow upper compression mold 4 and compressing in a heated state. The time for removing the liquid component contained in the molding material 35 after dehydration can be shortened, and the change with time in the thickness of the molding material 35 after compression can be suppressed.

Further, during the compression, by compressing in the vacuum suction state from the discharge port 12 of the hollow lower compression mold 2, it is possible to shorten the time for removing the liquid component contained in the molding material 35 after filtration and dehydration.

Note that the discharging step and the compressing step may be performed simultaneously, or the compressing step may be performed after the discharging step.

If performed in order, the dispersion medium and the molding material can be sufficiently separated first, so when the upper mold is heated during compression in the compression process, the molding material is compressed with less temperature drop. Can do. When it is performed simultaneously, the molding material can be manufactured in a shorter time since the process for one process can be reduced.

<Molding process>
Regarding the step of forming a resin molding by curing the molten resin after impregnating the reinforcing fiber layer made of short fibers with the molten resin generated by pressurizing the molding material 35 while heating and melting the powdered resin. This will be described below.

As shown in FIG. 6, a resin-made rotating body half-finished product 40 provided with a molding material 35 on a bush 31 is placed in a preheated mold 41 and then heated and pressed to cure the powdered resin. Then, the resin rotating body provided with the resin molded body is molded. The mold 41 includes a fixed mold 42, a movable mold 43 that is disposed at the center of the fixed mold 42 and is displaced in the vertical direction, and an upper mold 44 that sandwiches the bush 31 in pairs with the movable mold 43. And. When the pressing portion 44 </ b> A of the upper mold 44 is inserted into the fixed mold 42 and presses the bush 31, the moving mold 43 is displaced downward according to the amount of insertion of the upper mold 44. When the resin is cured, the resin rotating body including the resin molded body formed with the molding material 35 as the core material is taken out from the mold 41 to complete the production of the resin molded body.

<Processing process>
Gear cutting is performed on the outer periphery of the resin molded body impregnated and cured with resin. The teeth can be added at the time of mold forming or can be added by cutting after the mold forming. However, since the accuracy can be increased, it is preferable to provide the teeth by cutting.

<Second Embodiment>
In the first embodiment, a slurry is made by mixing short fibers, a powdered resin, and water. When such a slurry is used, since the viscosity of the slurry is low, for example, the mesh size of the wire mesh used for the bottom member 39 of the hollow lower compression mold 2 shown in FIG. 1 is reduced (the mesh of the wire mesh is increased). And the yield of the short fiber and the powdery resin in the molding material 35 is deteriorated. Therefore, for example, when using a wire mesh having a mesh size of 100 μm on one side, if the particle size of the powdered resin is 10 μm, the amount of the powdered resin that is discharged together with water due to poor filtration performance Will increase. To prevent such a situation, increasing the mesh size (decreasing the mesh of the wire mesh) increases the filtration performance but increases the dehydration time. Therefore, in the second embodiment, in order to cope with such a problem, one or more types of electrostatic attraction aggregation type polymer flocculants are added to a mixed liquid in which short fibers, a powdered resin, and a dispersion medium are mixed. To adjust the slurry. When an electrostatic attraction aggregation type polymer flocculant is added, the electrostatic attraction aggregation type polymer flocculant functions not only as an aggregating function but also as a fixing agent. The powdered resin is fixed. As a result, the amount of short fibers and powdered resin remaining in the aggregate can be increased. That is, the fixing ratio between the short fibers and the powdered resin can be increased, and the yield can be improved.

The electrostatic attraction aggregation type polymer flocculant that can be used may be any one as long as it can increase the fixing rate of short fibers and powdered resin and does not significantly impair dehydration, As the cationic polymer flocculant, for example, a styrene polymer, a polyamine condensate, a dicyandiamide condensate, a cation-modified acrylic copolymer, a polymethacrylate ester, and a polyamidine hydrochloride can be used. Examples of the anionic polymer flocculant include acrylic copolymers, sulfonated polyphenols, polyhydric phenol resins, polyacrylate esters, and polyacrylate soda / amide derivatives.

In a flocculation method using a typical polymer flocculant, a cationic polymer flocculant is added to a mixed solution, and then an anionic polymer flocculant is added. When a cationic polymer flocculant is added to the mixed solution, a large number of aggregates called flocs are formed which are formed by collecting some short fibers and some powdered resin. Thereafter, when an anionic polymer flocculant is added, flocs gather to generate larger flocs, and a large number of flocs having large dimensions are formed. When such a floc is formed, the dewaterability is improved. As a result, dehydration can be performed in a short time, and the fixing rate between the short fibers and the powdered resin is improved. In particular, when a cationic styrene polymer aqueous solution is used as the cationic polymer flocculant and an anionic acrylic polymer aqueous solution is used as the anionic polymer flocculant, high dehydrating properties can be obtained.

Moreover, an amphoteric polymer flocculant can be used as the polymer flocculant. Amphoteric polymer flocculants are the neutralization effect (cations) of short fibers and powdered particles in the mixture, the formation of entanglement (high molecular weight) by polymer chains, and the entanglement (high molecular weight). It exerts an effect of reinforcing by electrostatic attraction due to charges of anions and cations. As such an amphoteric polymer flocculant, for example, an acrylamide / acrylic acid / alkylamino acrylate quaternary salt copolymer, a polyacrylic acid ester, or a polymethacrylic acid ester can be used.

Hereinafter, examples of the present invention will be described.

[Example 1]
In order to manufacture the slurry, a tank filled with water in such an amount that the concentration at the time of charging the short fibers and the powdered resin is 4 g / liter is prepared. And in this tank, the short fiber of the quantity which the fiber total amount of the short fiber in a resin molding becomes 40 volume%, and the powdery resin of the quantity which the total amount of resin in a resin molding becomes 60 volume% are put. Specifically, as a fiber chop used as a short fiber, a para-aramid fiber having an aspect ratio of 200 “Technola (trademark)” manufactured by Teijin Limited is 50% by mass, and a meta-aramid fiber having an aspect ratio of 200 “Teijin ( 45% by weight of “Conex (trademark)” manufactured by Co., Ltd., and 5% by weight of fine fiber “Kevlar (trademark)” manufactured by DuPont Co., Ltd., which has been fibrillated to a freeness value of 300 ml. Also, a phenol resin powder “Bellepearl (trademark)” manufactured by Air Water Bellpearl Co., Ltd. having a particle diameter of 20 μm is introduced as the powdery resin. Next, the water in the tank is stirred with a stirrer to disperse the fiber chop and the phenol resin powder to produce a slurry.

At this time, after adding and stirring a cationic styrene-based polymer aqueous solution marketed by Meisei Chemical Industry Co., Ltd. under the name of “Cerafix ST” (trademark) as a cationic polymer flocculant, an anionic polymer flocculant As a slurry used in this example, an anionic acrylic polymer aqueous solution marketed by Meisei Chemical Industry Co., Ltd. under the name of “FIREX M” (trademark) was added and stirred. The addition amount of the cationic styrenic polymer aqueous solution is 0.2% by mass with respect to the total amount of the short fibers and the powder resin, and the addition amount of the anionic acrylic polymer aqueous solution is the short fibers and the powder resin. The total amount was 0.1% by mass.

Next, using the filtration dehydration compression apparatus shown in FIG. 1 (A), the metal bush 31 is positioned on the bush support 5 and the slurry diffusion member 7 is placed on the metal bush 31 so as not to be displaced. Then, the metal bush 31 is sandwiched. In addition, the central angle of the conical surface of the conical slurry diffusing portion 71 protruding upward from the slurry diffusing member 7 is 90 °. Moreover, the top part of the slurry diffusion part 71 was made into the curved surface shape of R15mm.

The shape of the protrusion 33 and the recess 34 of the metal bush 31 to be used (see FIG. 4) is h1 = 2 mm and h2 = 0.5 mm, and is an undercut shape. Is 20 °.

Here, the position of the hollow lower compression mold 2 was a position where the distance from the axial center of the metal bush 31 to the upper surface of the bottom member 39 was 50 mm.

1) The slurry injection upper mold 20 and the cylindrical mold 3 shown in FIG. 1B are brought into close contact with each other, and the slurry is put into the filtration dehydration compression apparatus. Then, by sucking the inside of the cylindrical mold by vacuum and draining water from the plurality of outlets 12 provided in the hollow lower compression mold 2, the fiber chop, the phenol resin powder, and the water are separated to form a cylindrical short An aggregate 38 of fibers and powdered resin is obtained. After vacuum suction and separation of the fiber chop, phenol resin powder, and water, water is injected from the slurry injection hole 21, and the fiber chop and phenol resin powder remaining on the upper side of the slurry diffusion member 7 are washed away. The slurry injection hole 21 is disposed immediately above the slurry diffusion member 7.

In addition, in order to prevent the fiber chop and the phenol resin powder from flowing out from the discharge port 12 during drainage, a bottom member 39 is disposed on the hollow lower compression mold 2. As the bottom member 39, a metal: 20 mesh wire mesh was used.

Next, the metal bush 31 is compressed in order to allow the fiber chop and the phenol resin powder to bite into the non-rotating portion of the metal bush 31 more firmly. As shown in FIG. 1C, the hollow lower compression mold 2, the cylindrical mold 3, and the bush support stand up to a position where the distance from the axial center of the metal bush 31 to the lower surface of the hollow upper compression mold 4 is 50 mm. 5. The bush 31, the slurry diffusing member 7, the short fiber and powder resin aggregate 38 are raised together with the base 1. This position is a position where the metal bush 31 is located in the center between the hollow upper compression mold 4 and the hollow lower compression mold 2.

As shown in FIG. 1D, the pedestal 1 is raised at a speed of 1 to 5 mm / s while the bush 31 is located at the center between the hollow upper compression mold 4 and the hollow lower compression mold 2. Compress until the aggregate 38 of the fiber and the powdery resin has a thickness of 20 mm.

And by compressing for 2 minutes in this state, a semi-finished product for molding a resin rotating body integrated with the metal bush 31 was obtained.

In addition, at the time of the said compression, it compresses in the state vacuum-sucked from the discharge port 12 of the hollow lower compression type | mold 2. 5B, the length of the bush support base 5: L7 = 100 mm, the length of the slurry diffusion member 7: L6 = 70 mm, the length of the pressing member 8: L5 = 30 mm, the metal bush 31 Thickness: T1 = 10 mm, height L3 and L4: L3 = L4 = 100 mm of the step portions of the hollow upper compression mold 4 and the hollow lower compression mold 2.

[Example 2]
A molding material was produced in the same manner as in Example 1 except that the top of the slurry diffusion member 7 was not curved.

[Comparative Example 1]
A molding material was produced in the same manner as in Example 1 except that the remaining short fibers and powdered resin adhering to the slurry diffusing member 7 were not washed away.

After slurry injection by the methods shown in Examples 1 and 2 and Comparative Example 1 described above, the number of remaining short fibers and powdered resin on the slurry diffusing member 7 is measured (short fibers and powder during 10 molding material preparations). The remaining number of resin was measured). The measurement results are shown in Table 1 below.

From Table 1, in Comparative Example 1 in which the short fibers and the powdered resin were not washed away, the short fibers and the powdered resin remained on the slurry diffusion member 7 out of 10 times. In addition, even in the case where the cleaning water was added, in Example 2 where the top of the slurry diffusing member 7 was not curved, the short fibers and the powdered resin remained on the slurry diffusing member 7 five times out of ten times. In contrast, in Example 1 in which the top portion of the slurry diffusion member 7 was curved, the short fibers and the powdered resin remained on the slurry diffusion member 7 only 0 times. Therefore, compared with the comparative example 1, in this invention including the washing | cleaning process which wash | cleans the short fiber and powdery resin which adhere and remain | survive to a slurry diffusion member at a charging process, a short fiber and powdery resin do not remain on the slurry diffusion member 7. Therefore, there is little variation in the amount of individual short fibers and powdered resin, and there is no mold damage, so continuous production can be performed.

In the above example, since the polymer flocculant is added to the slurry, the coagulability is high, and only in the case of Example 1, a sufficient cleaning effect is obtained. However, in the case where the polymer flocculant is not added to the slurry as in the first embodiment, a slurry diffusing portion having a curved surface at the tip portion is used like the slurry diffusing member used in Example 1 above. In addition, it has been confirmed by experiments that a sufficient cleaning effect can be obtained even when a slurry diffusing portion having no curved surface at the tip portion, such as the slurry diffusing member used in Example 2 above, is used. Therefore, the shape of the slurry diffusing member does not need to have a curved surface at the tip as in the slurry diffusing member of the first embodiment, depending on the viscosity of the slurry. The slurry diffusing portion of the slurry diffusing member can be used in the present invention as long as the area of the cross section extending in at least the upper direction and perpendicular to the upper direction becomes smaller in the upward direction.

According to the present invention, the molding produced by pouring the dispersion medium or water toward the slurry diffusing member, and dropping the short fibers and the powdered resin remaining attached to the slurry diffusing member into the cylindrical mold. It is possible to perform continuous production by making the basis weight (mass) of the material uniform and preventing the base material from biting the short fiber and the powdered resin into the gap between the mold members. In addition, the mold life can be extended.

In addition, when the discharging process for discharging the dispersion medium from the cylindrical mold and the process for compressing the aggregate of short fibers and powdered resin are performed at the same time, the molding material can be manufactured in a shorter time because the process for one process can be reduced. can do.

When the dispersion medium is discharged in a reduced pressure atmosphere, the dispersion medium can be discharged in a shorter time.

When the compression step of compressing the aggregate of short fibers and powdered resin is performed at a pressure of 5 to 25 MPa, more dispersion medium contained in the aggregate of short fibers and powdered resin can be discharged. it can. In addition, the bond strength between the short fiber and powdered resin aggregate and the anti-rotation portion provided on the metal bush is increased, and the short fiber and powder resin aggregate is also tightly clamped, making the molding material easy to handle. improves.

In addition, when carried out while applying heat, the dispersion medium contained in the aggregate of the short fibers and the powdered resin can be separated in a short time by setting the temperature lower than the melting temperature of the powdered resin. When further heating is performed in a reduced-pressure atmosphere, separation can be performed in a shorter time.

When the aggregate of short fibers and powdered resin is given the shape of a gear in a cylindrical mold, the final cutting process can be simplified when the gear is finally produced. Yield can be improved.

Since the resin rotating body of the present invention has a uniform basis weight of the molding material, it has uniform strength, excellent durability, and can withstand high temperature / high load use conditions such as vehicle parts and industrial parts. It can be used as a resin rotating body.

DESCRIPTION OF SYMBOLS 1 Base 2 Hollow lower compression type 3 Cylindrical die 4 Hollow upper compression type 5 Bush support stand 6 Lower elastic body 7 Slurry diffusion member 8 Pressing member 9 Upper elastic body 10 Step part 11 Step part 12 Discharge port 13 Filtration dehydration compression apparatus 20 Slurry injection upper mold 21 Slurry injection hole 30 Resin gear 31 Metal bush 32 Through hole 33 Protrusion 34 Recess 35 Molding material 36 Outer part 37 Resin molded body 38 Aggregate of short fibers and powdered resin 39 Bottom member 40 Resin Semi-finished product 41 for forming a rotating body 41 Mold 42 Fixed mold 43 Moving mold 44 Upper mold 44A Pressing part

Claims

An adjustment step of preparing a slurry in which short fibers and powdered resin are dispersed in a dispersion medium;
A cylindrical mold having an opening that opens upward, and an area of a cross section that is disposed at the center of the cylindrical mold and extends in the upward direction and perpendicular to the upward direction is the upward direction. In a molding die including a slurry diffusing member having a slurry diffusing portion having a shape that decreases as it goes to, a charging step of charging the slurry from the upper direction toward the slurry diffusing portion;
After the charging step, the same dispersion medium or water as the dispersion medium is poured from above toward the slurry diffusion part, and the short fiber adhering to the slurry diffusion part and the powdery resin are dropped, and
Discharging the dispersion medium or the dispersion medium and the water from the molding die to form an aggregate in which the short fibers and the powdery resin are aggregated in the molding die. The manufacturing method of the molding material to do.
The method for manufacturing a molding material according to claim 1, wherein a compression step is performed in which the aggregate is compressed to form a molding material during or after the discharging step.
In the adjustment step, the slurry is adjusted by adding one or more kinds of electrostatic attraction aggregation type polymer flocculants to a mixed liquid obtained by mixing the short fibers, the powdered resin, and water,
The method for producing a molding material according to claim 1, wherein the slurry diffusing portion of the slurry diffusing member has a curved surface that protrudes upward at a tip portion.
The molding material according to claim 3, wherein a cationic polymer flocculant is added to the mixed liquid and then an anionic polymer flocculant is added to the mixed liquid as the one or more types of electrostatic attraction aggregation type polymer flocculants. Manufacturing method.
4. The method for producing a molding material according to claim 3, wherein an amphoteric polymer flocculant is added to the mixed solution as the one or more types of electrostatic attraction aggregation type polymer flocculants.
The method for producing a molding material according to claim 4, wherein the cationic polymer flocculant is a cationic styrene polymer aqueous solution, and the anionic polymer flocculant is an anionic acrylic polymer aqueous solution.
The method for producing a molding material according to claim 1, wherein in the cleaning step, a predetermined amount of the dispersion medium or water is injected a plurality of times at predetermined time intervals.
The predetermined time interval is a time interval required for the level of the previously injected dispersion medium or water to fall below the top surfaces of the short fibers and the powdery resin layer that have already dropped. The manufacturing method of the shaping | molding raw material of Claim 7.
The opening of the cylindrical mold is closed by a lid member having a nozzle extending downward in the center in the charging step and the cleaning step,
2. The manufacturing of a molding material according to claim 1, wherein the nozzle has a length and a tip shape so that the dispersion medium or the water is intensively charged onto the slurry diffusion portion in the cleaning step. Method.
The method for producing a molding material according to claim 1, wherein the discharging step is performed under a reduced pressure atmosphere in the discharge port.
The method for producing a molding material according to claim 2, wherein the compression step is performed at a pressure of 5 to 25 MPa.
The method for producing a molding material according to claim 2 or 11, wherein the compression step is performed while applying heat at a temperature lower than a melting temperature of the powdered resin.
A molding die used in the method for producing a molding material according to claim 1,
A cylindrical mold having an opening that opens upward, and an area of a cross section that is disposed at the center of the cylindrical mold and extends in the upward direction and perpendicular to the upward direction is the upward direction. Including a slurry diffusion member having a slurry diffusion portion having a shape that decreases as it goes to
The molding die, wherein the slurry diffusing portion of the slurry diffusing member has a curved surface that protrudes upward at the tip thereof.
The molding die according to claim 13, wherein a radius of curvature of the curved surface is 10 mm or more and 20 mm or less.
A molding material produced by the method of any one of claims 1 to 12 is impregnated in a reinforcing fiber layer made of short fibers with a molten resin produced by applying pressure while heating to melt the powdered resin. Thereafter, a method of manufacturing a resin rotating body by further performing a molding step of curing the molten resin to form a resin molded body.
The method for producing a resin rotating body according to claim 15, wherein a gear cutting process is performed on an outer peripheral portion of the resin molded body after the molding step.
A resin rotating body manufactured by the resin rotating body manufacturing method according to claim 15 or 16.